US10105568B2 - Stair climber apparatuses and methods of operating stair climber apparatuses - Google Patents

Abstract

Stair climber apparatuses have a control circuit that controls the speed and torque of an electric motor and controls an output torque direction of the electric motor. The control circuit controls the speed of the electric motor and the output direction of the electric motor to maintain a constant speed of travel of a plurality of stairs in a downward direction along an inclined support when an operator is stepping on the plurality of stairs in an upward direction. When a change in output torque direction of the electric motor torque is required to maintain the constant speed of travel of the plurality of stairs in the downward direction along the inclined support, the control circuit controls the speed of the electric motor down to a zero speed. Methods are for operating the stair climber apparatuses.

Description

FIELD

The present disclosure relates to exercise equipment, for example stair climber apparatuses and methods of operating stair climber apparatuses.

BACKGROUND

U.S. Pat. No. 4,927,136 discloses an electromechanical and more particularly an electromagnetic brake that is utilized in the control of exercise equipment including escalator type stair-climbing apparatus, in which electronically controllable torque, including a clamping torque, is applied to a rotary shaft to load the exercise equipment, thereby giving complete electronic control to the operation of the exercise apparatus including a safety locking function.

U.S. Pat. No. 5,120,050 discloses a step type exerciser that comprises an endless loop of steps in which each step has an associated pair of pulleys, one at each end, and these run on fixed “inside out” Vee belts. This provides a particularly inexpensive guide means which is quiet in running. Drive is transmitted by toothed pinion blocks carried adjacent to each roller but angularly fixed whereas the rollers are rotatable, and the blocks engage a second belt which is driven by a motor.

U.S. Pat. No. 5,145,475 discloses an exerciser that provides low impact exercise for the upper and lower body of an operator. The apparatus includes an upper portion having moving rungs simulating a hand-over-hand motion to exercise one's upper body and a lower portion having moving platforms simulating a stair-like climbing motion to exercise one's lower body. The upper and lower portions are oriented at different angles to maximize operator comfort, the angle of the lower portion in particular providing clearance for one's knees during use. The exerciser also includes a variable speed control to adjustable vary the speed of the moving rungs and platforms, thereby adapting to the needs of various operator's.

U.S. Pat. No. 5,328,420 discloses a stair step exerciser that is mounted on a frame having horizontal and vertical components. A carriage comprised of a pair of side plates is pivoted to one end of a horizontal component and is retained at the other end in one of a series of vertical stops to selectively determine the angle of the carriage with respect to the frame. The carriage has pulleys at both ends which support the belts on which treads are pivoted at one end. The other end of the treads rest on one rail of a four bar linkage, which linkage expands as the carriage angle is decreased and collapses as the carriage angle is increased so as to always maintain the treads horizontal. A pair of hand cables is provided which move at substantially the same speed as the treads. The hand cables are mounted so as to be closer to the treads as the angle of the carriage increases and so as to move away from the treads as the angle of the carriage decreases.

U.S. Pat. No. 5,556,352 discloses a stair exerciser having a plurality of revolvable steps supported by endless chain conveyors and a control device for speed control, which, by the weight and action of an operator walking on the steps, enables the mechanism to run cyclical and continuous action thereby affording the operator stair climbing like exercises.

U.S. Pat. No. 5,769,759 discloses an apparatus for simulating stair climbing which allows selection of step height. A side member is pivotally mounted to a base and oriented at a selected angle with respect to the base. A displacement mechanism mounted to the base is attached to the side member for rotating the side member with respect to the base. A series of platforms travels in a selected platform path including traveling along the side member. The top surface of each platform is a predetermined horizontal distance from the top surface of an adjacent platform which corresponds to the selected angle.

SUMMARY

This Summary is provided to introduce a selection of concepts that are further described herein below in the Detailed Description. This Summary is not intended to identify key or essential features of the claimed subject matter, nor is it intended to be used as an aid in limiting the scope of the claimed subject matter.

In certain examples, a stair climber apparatus can comprise a frame having an inclined support that extends from a bottom portion to a top portion. Stairs in a plurality of stairs are connected together in series and travel in a loop around the inclined support. An electric motor is operably connected to the plurality of stairs. The electric motor operates to move the plurality of stairs in an upward direction along the inclined support and alternately operates so as to move the plurality of stairs in an opposite, downward direction along the inclined support. A control circuit controls a speed of the electric motor and controls an output torque or force direction of the electric motor between the forward direction and the reverse direction. The control circuit controls the speed of the electric motor and the output torque direction of the electric motor to maintain a constant speed of travel of the plurality of stairs in the downward direction along the inclined support when an operator is stepping on the plurality of stairs in the upward direction. When a change in output torque or force direction of the electric motor is required to maintain the constant rate of change of speed of travel of the plurality of stairs in the downward direction, the control circuit controls the speed of the electric motor down to a zero speed.

In certain other examples, methods are for operating a stair climber apparatus having an inclined support that extends from a bottom portion to a top portion; and a plurality of stairs that are connected together in series and travel in a loop around the inclined support. The methods can comprise controlling a speed and output torque or force direction of electric motor that is operably connected to the plurality of stairs, wherein the electric motor operates to move the plurality of stairs in an upward direction along the inclined support and wherein the electric motor alternately operates so as to move the plurality of stairs in an opposite, downward direction along the inclined support. The methods can further comprise controlling the speed of the electric motor and the output torque or force direction of the electric motor to maintain a constant speed of travel of the plurality of stairs in the downward direction along the inclined support when an operator is stepping on the plurality of stairs in the upward direction; and controlling the speed of the electric motor down to a zero speed when a change in output torque or force direction of the electric motor is required to maintain the constant speed of travel of the plurality of stairs in the downward direction.

BRIEF DESCRIPTION OF DRAWINGS

Examples of stair climber apparatuses and methods of operating stair climber apparatuses are described with reference to the following drawing figures. The same numbers are used throughout the figures to reference like features and components.

FIG. 1 is a perspective view of a stair climber apparatus.

FIG. 2 is a perspective view of the apparatus shown inFIG. 1, having some parts removed for illustration.

FIG. 3 is a side view of the apparatus shown inFIGS. 2 and 3, having additional parts removed for illustration.

FIG. 4 is a closer view of an electric motor and mechanical brake on the apparatus ofFIG. 1.

FIG. 5 is a view of a stair apparatus that comprises a plurality of stairs that are pivotably connected together in series and travel in a loop.

FIG. 6 is a side view of the stair apparatus shown inFIG. 5.

FIG. 7 is an exploded view of a stair apparatus shown inFIG. 5.

FIG. 8 is a flow chart showing one example of a method of operating the stair climber apparatus shown inFIGS. 1-7.

FIG. 9 is a flow chart showing another example of a method of operating the stair climber apparatus shown inFIGS. 1-7.

FIG. 10 is a flow chart showing yet another example of a method of operating the stair climber apparatus shown inFIGS. 1-7.

DETAILED DESCRIPTION OF DRAWINGS

In the present Description, certain terms have been used for brevity, clearness and understanding. No unnecessary limitations are to be implied therefrom beyond the requirement of the prior art because such terms are used for descriptive purposes only and are intended to be broadly construed. The different stair climber apparatuses, stair apparatuses, systems and methods described herein may be used alone or in combination with other apparatuses, systems and methods. Various equivalents, alternatives and modifications are possible within the scope of the appended claims. Each limitation in the appended claims is intended to invoke interpretation under 35 U.S.C. § 112, sixth paragraph only if the terms “means for” or “step for” are explicitly recited in the respective limitation.

FIGS. 1-4 depict personal exercise equipment, namely astair climber apparatus10 having astair apparatus11. Thestair climber apparatus10 has aframe12 that defines aninclined support14 extending from alower end portion16 to anupper end portion18. A plurality ofstairs20 are connected together in series and travel together in a loop around theinclined support14. Anelectric motor22 is operatively connected to the plurality ofstairs20, as will be described further herein below. The type ofelectric motor22 can vary, and in this example includes a conventional asynchronous electric motor, one example of which can be commercially obtained from Eul Ji. During operation, theelectric motor22 can be controlled to rotate anoutput shaft28 in a first direction (e.g. forward or clockwise) to move the plurality ofstairs20 in adownward direction24 with respect to theinclined support14, and alternately to rotate theoutput shaft28 in an opposite, second direction (e.g. reverse or counter-clockwise) to move the plurality ofstairs20 in anupward direction26 with respect to theinclined support14, all as will be further described herein below. Theelectric motor22 can be operated as a brake to maintain constant speed of movement of the plurality ofstairs20 as an operator steps upwardly on the plurality of stairs20 (thus providing downward force on the stairs), and/or to slow the speed of movement of the plurality ofstairs20 down to a zero speed, as will be discussed further herein below.

Referring toFIGS. 2-4, rotation of theoutput shaft28 of theelectric motor22 rotates adrive belt30, which is connected to and rotates a pulley32 (seeFIGS. 3 and 4) about a centerlive shaft34. Thedrive belt30 is tensioned by a spring31 that biases an idler roller29 about a pivot point33 and against thedrive belt30. Rotation of thepulley32 about its centerlive shaft34 causes corresponding rotation of alower sprocket36. Rotation of thelower sprocket36 causes rotation of a vertically-orientedchain38 around a loop. The vertically-orienteddrive chain38 rotates around thelower sprocket36 and anupper sprocket40. Thechain38 is tensioned by anidler sprocket42 that abuts against thechain38 and is laterally adjustable by anadjustment plate45 that can be fixed at several different positions with respect to theframe12 to modify the tension. Rotation of thechain38 causes rotation of theupper sprocket40 and its centerlive shaft43. Rotation of theupper sprocket40 and the centerlive shaft43 causes synchronous rotation of a pair of inner sprockets42 (only one shown inFIG. 2) that are located on opposite sides of theinclined support14 and are keyed to the centerlive shaft43 for rotation therewith. Rotation of the pair ofinner sprockets42 causes rotation of a pair ofdrive chains44 that are located on opposite sides of theinclined support14. The pair ofdrive chains44 angularly extends along theinclined support14 and is driven in a loop around a lower pair ofsprockets46 and centerlive shaft47, which are located at thelower end portion16 of theinclined support14.

Thedrive chains44 support the plurality ofstairs20 as thestairs20 travel in the noted loop around theinclined support14. Each of thestairs20 has atread64 and ariser66. Thetread64 and theriser66 are pivotably connected together at a conventional hinge formed by apivot shaft21 that extends along a first pivot axis68 (seeFIGS. 5 and 7). Thetread64 has atread surface70 that supports an operator's foot73 (seeFIG. 6) as the operator steps onto thestair20. Eachstair20 in the plurality is connected to anadjacent stair20 in the plurality by apivot shaft41 that extends along a second pivot axis99 (seeFIGS. 5 and 7) that is parallel to thefirst pivot axis68. Thepivot shaft21 has opposite ends23 that carrybearings25. Each bearing25 is attached to one of the pair ofdrive chains44 and is configured to ride along a bearingsupport27 that extends along theinclined support14 from thelower end portion16 to theupper end portion18.

Rotation of the pair ofdrive chains44 carries thebearings25 around theinner sprockets42 at theupper end portion18 and around thelower sprockets46 at thelower end portion16. As thebearings25 rotate around theinner sprockets42 andlower sprockets46, thebearings25 are fed into the bearingsupport27 and received from the bearingsupport27, or vice versa depending upon the direction of operation of theelectric motor22. Thestairs20, via thebearings25 and thepivot shafts21, travel with the pair ofdrive chains44 around therespective sprockets42,46. During said movement, thestairs20 pivot by gravity with respect to each other along thepivot shafts41. Thetread64 andriser66 of eachstair20 also pivot by gravity with respect to each other along thepivot shafts21. Thestairs20 are configured so that theriser66 pivots towards thetread64 up until thebearings25 begin to ride along the bearingsupport27. As thebearings25 exit the bearingsupport27, thetread64 andriser66 are configured to pivot away from each other. These pivoting movements of thestairs20 are shown inFIG. 6.

Referring toFIG. 4, theelectric motor22 is connected to amechanical brake48 via abraking belt50. The type ofmechanical brake48 can be a conventional item and in one example themechanical brake48 can include a solenoid actuator that actuates a brake pad to prevent movement of apulley52. Actuation of themechanical brake48 prevents rotation of apulley52 about itscenter shaft54, which in turn prevents rotation of theelectric motor22 via thebraking belt50.

Thestair climber apparatus10 also has acontrol circuit110 for controlling movement of thestair apparatus11. Thecontrol circuit110 includes a programmable processor, a memory, a timer, and an input/output device. The processor is communicatively connected to a computer readable medium that includes volatile or nonvolatile memory upon which computer readable code is stored. The processor can access the computer readable code on the computer readable medium, and upon executing the code, can send signals to carry out functions according to the methods described herein below. Execution of the code allows thecontrol circuit110 to control (e.g. actuate) a series of devices on thestair climber apparatus10, including but not limited to theelectric motor22. Thecontrol circuit110 may also read values from sensors, and interpret the data using look-up tables or algorithms stored in the memory. Such sensors can include but are not limited to anencoder111 for detecting and communicating speed and direction of the plurality ofstairs20 to controlcircuit110. Such sensors can also include, for example, sensors associated with various operator input devices, which will be further described herein below. Thecontrol circuit110 can be connected to the devices (such as for example theelectric motor22 and various sensors) with which it communicates via conventional wired and/or wireless communication links. It should be noted that the dashed lines shown inFIGS. 1 and 2 are meant to show only that various devices are capable of communicating with thecontrol circuit110, and do not necessarily represent actual wiring connecting the devices, nor do they represent the only paths of communication between the devices. Further, it should be understood that thecontrol circuit110 could additionally or alternatively have many separate and/or communicatively interconnected control circuits or control units/sections at various locations on thestair climber apparatus10.

As mentioned above, several operator input devices are provided on thestair climber apparatus10 for communicating operator commands to thecontrol circuit110. The operator input devices can include, for example one or more conventional video/touch control panels114 and/or one or more conventional speedcontrol push buttons116 located onhandle members118. The video/touch control panels114 and/orbuttons116 can communicate operator inputs to thecontrol circuit110 for operating thestair climber apparatus10 according to one or more predetermined exercise programs having certain time periods and providing certain resistance characteristics. Additional the operator input devices can include, for example heart rate monitors119 located on thehandle members118 for communicating heart rate of the operator for communication to thecontrol circuit110. The operator input devices are not limited to these types of devices and can also or alternatively include devices for providing output devices such as visual, audial, tactile, and/or other sensory feedback to the operator. The operator inputs to thecontrol circuit110 via the operator input devices are acted upon by thecontrol circuit110 to control operation of thestair climber apparatus10 according to various programs, which include programs for affecting the speed and direction of movement of the plurality ofstairs20 via theelectric motor22. Thus, when the operator is located on thestair climber apparatus10, the operator can input, via the various input devices, speed commands to thecontrol circuit110 for controlling speed of movement and direction of movement of the plurality ofstairs20, as will be understood by those having ordinary skill in the art. A operator boarding (i.e. second)operator input device120 is also located at thelower end portion16 of theinclined support14 and will be described further herein below.

During operation, as the operator steps forwardly (i.e. in the upward direction26) along theinclined support14, theelectric motor22 rotates theoutput shaft28 to move the plurality ofstairs20 in thedownward direction26 with respect to theinclined support14. A specific speed of movement of the plurality ofstairs20 can be selected (i.e. set) by the operator via one of the noted input devices. Based upon this input, thecontrol circuit110 is programmed to control the output torque and speed of theelectric motor22 to maintain the speed of movement of the plurality of stairs at a constant speed selected by the operator, despite physical characteristics of the operator and/or the changes in stepping speed of the operator. The speed of thestairs20 and direction of movement of thestairs20 is sensed and communicated to thecontrol circuit110 via theencoder111, as is conventional. Based upon this information, thecontrol circuit110 adjusts the power (e.g. current) to theelectric motor22 to thereby affect the speed of theelectric motor22. Power can be supplied to theelectric motor22 via a conventional power cord, and/or one or more batteries, and/or the like.

Referring toFIGS. 5-7, through research and development, the present inventor has recognized that as eachstair20 travels around theupper sprocket40 and into thedownward direction24, theriser66 pivots from an angle A with respect to thetread64 to a lesser angle B with respect to thetread64. Through research, it has been found that operators often step onto theuppermost tread surface70 on theinclined support14 at the same time as when theriser66 is pivoting towards thetread surface70. In such situations, if the operator oversteps the first pivot axis68 (i.e. the operator's toe oversteps the tread surface), the operator'stoe79 can be impinged upon or pinched by theriser66 as it pivots into the angle B. This can undesirably result in discomfort and/or injury to the operator.

To prevent such an occurrence, one or a plurality of stoppingmembers72 is disposed on thetread64 of each of thestairs20 in the plurality ofstairs20. Referring to one of the stairs (i.e. a first stair) inFIG. 7, each stoppingmember72 has astop surface74 that extends transversely upwardly from thetread surface70. Thestop surface74 is configured to block and thereby prevent the operator'sfoot73 from overshooting thefirst pivot axis68 and engaging theriser66 as the operator steps onto thetread surface70 when theriser66 is pivoted out of the perpendicular angle B (seeFIG. 6) with respect to thetread64 and more particularly with respect to thetread surface70. This feature prevents the operator'stoe79 and/or other body part from becoming impinged or pinched by thetread64 as thetread64 pivots from the angle shown at A inFIGS. 5 and 6 towards the angle shown at B inFIGS. 5 and 6.

The particular physical configuration of the stoppingmembers72 and associated stop surfaces74 can vary from that which is shown. In this example, thestop surface74 is planar and extends perpendicular to thetread surface70. Each stoppingmember72 in the plurality is spaced apart from the other stoppingmembers72 in the plurality, and the plurality of stoppingmembers72 are aligned with respect to thefirst pivot axis68. Thestop surface74 extends transversely to and upwardly from thetread surface70.

Referring toFIG. 7, theriser66 has a plurality ofprojections76 that are interdigitated amongst the plurality of stoppingmembers72 along thefirst pivot axis68. Thefirst pivot axis68 andpivot shaft21 extend through the plurality of stoppingmembers72 and the plurality ofprojections76. The plurality ofprojections76 also each have stop surfaces78 that are aligned with the stop surfaces74 of the plurality of stoppingmembers72 when theriser66 is positioned at the noted angle B to thetread surface70. The plurality of stop surfaces78 of the plurality ofprojections76 is planar. The plurality ofprojections76 are spaced apart along thefirst pivot axis68 so as to define a plurality ofrecesses80 in which the plurality of stoppingmembers72 are disposed. Eachrecess80 has atop edge82 and each stoppingmember72 has acurved back surface84 alongside of which thetop edge82 travels as theriser66 is pivoted with respect to thetread64.

Eachtread64 includes afront edge86 and aback edge88. Eachriser66 includes afront edge90 and aback edge92. Theback edge88 of thetread64 is pivotably connected to thefront edge90 of theriser66 at the notedfirst pivot axis68. In this manner, the plurality of stoppingmembers72 prevent any portion of the operator'sfoot73 from overshooting theback edge88 of thetread64 as the operator steps onto thetread surface70 when theriser66 is pivoted out of the angle B with respect to thetread64.

Referring toFIG. 6, eachadjacent stair20 in the plurality also has thetread64 and theriser66. Thetread64 of an adjacent (e.g. second)stair20 is pivotably connected to thetread64 of the notedfirst stair20 at thesecond pivot axis99, which is parallel to thefirst pivot axis68. Thetread64 andriser66 of theadjacent stair20 are pivotably connected together along afirst pivot axis68 that is parallel to thesecond pivot axis99. Like thefirst stair20, theadjacent stair20 has a stoppingmember72 having astop surface74 that extends transversely upwardly from atread surface70 of theadjacent stair20 so as to prevent the operator'sfoot73 from overshooting thesecond pivot axis99 and engaging theriser66 as the operator steps on thetread surface70 of theadjacent stair20 when theriser66 is pivoted away from thetread64 of theadjacent stair20. The remainingstairs20 in the plurality are similarly configured.

This disclosure thus provides a plurality ofstairs20 that travel in the noted loop around theinclined support14 in such a manner that when the operator'sfoot73 steps on the stair at theupper end portion18 of theinclined support14, the operator'stoe79 or any portion of the operator's body will not be impinged upon or pinched by theriser66 as theriser66 pivots around the centerlive shaft43 and moves from the angle A to the angle B with respect to thetread64. More specifically, the operator'stoe79 and/or other body parts will be blocked from overshooting thefirst pivot axis68 about which theriser66 pivots, thereby protecting the operator'stoe79 from becoming impinged upon or pinched.

During further research and development, the present inventors have determined that existing stair climber apparatuses do not consistently facilitate a safe reduction in speed of the plurality of stairs down to a zero speed. Rather, existing apparatuses that utilize passive resistance devices can only reduce the speed of the stairs to a certain point, where after application of a mechanical brake is necessary to achieve zero speed. Thus these apparatuses typically cause an abrupt transition from a non-zero speed to zero speed, which can be disconcerting to the operator and can cause undue wear and tear on the apparatus, including for example on the mechanical brake.

The presentstair climber apparatus10 is able to overcome these disadvantages because it employs theelectric motor22, which can be controlled by thecontrol circuit110 to resist and thereby more smoothly slow the speed of the plurality ofstairs20 down to a zero speed than passive resistance devices. Thereafter, themechanical brake48 can be actuated by thecontrol circuit110 from an unlocked position wherein output of theelectric motor22 to the plurality ofstairs20 is permitted to a locked position wherein output of theelectric motor22 to the plurality ofstairs20 is prevented.

During further research and development, the present inventors have also realized that in some instances, thestair climber apparatus10 can be difficult to board, especially when thelowermost stair20 at thelower end portion16 of theinclined support14 is not located close to the ground. That is, depending upon when movement of the plurality ofstairs20 was stopped during the previous use of thestair climber apparatus10, thelowermost stair20 in the plurality can often located a significant distance away from the ground, for example with anadjacent stair20 in the plurality being only partially rotated about thelower sprocket46. This can make it difficult for an operator to step up high enough to board thelowermost stair20. As a first solution to this problem, thestair climber apparatus10 has step-assiststeps61, which are fixed onto theframe12 and provide a fixed initial step for the foot of the operator. However, in addition to this solution, the inventors have realized that it also would be beneficial to allow the operator to temporarily control thestair climber apparatus10 to move the plurality ofstairs20 to thereby bring one of the plurality ofstairs20 closer to the ground, thus decreasing the height of which the operator needs to initially step up onto thestair climber apparatus10.

In some examples directed to these objectives, thestair climber apparatus10 includes the noted secondoperator input device120, which is located at thelower end portion16 of theinclined support14. In this example, the secondoperator input device120 is located on one of thehandles35 of theframe12 and is oriented outwardly with respect to the entryway to the plurality ofstairs20; however the location of the secondoperator input device120 can vary from that shown, as long as the secondoperator input device120 can be accessed by the operator when the operator is standing near thelower end portion16 of theinclined support14 prior to boarding thestair climber apparatus10. The secondoperator input device120 is electrically connected to thecontrol circuit110 via a wired or wireless link (not shown) and is thereby configured to input a boarding command from the operator to thecontrol circuit110. Upon receipt of the boarding command, thecontrol circuit110 can be programmed to control theelectric motor22 so as to move the plurality ofstairs20 along theinclined support14 to thereby facilitate an operator stepping up onto thelowermost stair20 in the plurality. In this particular example the secondoperator input device120 is a switch or pushbutton; however the type ofoperator input device120 can vary, similar to the various other operator input devices described herein above.

In certain examples, upon an operator's input of the boarding command, thecontrol circuit110 is programmed to control theelectric motor22 so as to move the plurality ofstairs20 in theupward direction26 along theinclined support14. The inventors have found that it can be advantageous to program thecontrol circuit110 to control theelectric motor22 to move the plurality ofstairs20 in theupward direction26 so that when the operator steps on thelowermost stair20, the movement of the plurality ofstairs20 in theupward direction26 helps lift the operator up onto theapparatus10.

Upon the operator's input of the boarding command, thecontrol circuit110 can be programmed to control theelectric motor22 for a predetermined time period. The length of the predetermined time period can be saved in the memory of thecontrol circuit110 and can be a time period that is sufficient to bring anext stair20 around the pair oflower sprockets46 and into a lowermost position (i.e. a position closest to the ground along the inclined support) in which the operator can place his or her foot onto thetread surface70. In certain other examples, based on the operator's input of the boarding command, thecontrol circuit110 is programmed to control theelectric motor22 so as to move the plurality ofstairs20 in the upward direction26 a predetermined distance along theinclined support14. The predetermined distance can be saved in the memory of thecontrol circuit110 and can be a predetermined minimum distance that is required to bring a new stair of the plurality ofstairs20 around the pair oflower sprockets46 and into the noted lowermost position. The lowermost position optionally can be a position in which thetread64 of thestair20 is horizontally positioned with respect to the ground; however this is not required. For example, the lowermost position can be a position in which thetread64 is positioned at an angle to the ground so that the leading edge (front edge86) of thetread64 is located closer to the ground than the trailing edge (back edge88) of thetread64, thus promoting an even easier first step up by the operator.

If thecontrol circuit110 is programmed to control theelectric motor22 so as to move the plurality ofstairs20 in theupward direction26, the lowermost position can be a position in which thestair20 has travelled all the way around the pair ofsprockets46 at thelower end portion16 of theinclined support14. If thecontrol circuit110 is programmed to control theelectric motor22 so as to move the plurality ofstairs20 in thedownward direction24, the lowermost position can be a position in which thestair20 has moved from a location on theinclined support14 to a lower position on theinclined support14, located closer to the ground. This may likely require that anadjacent stair20 travel around the pair ofsprockets46 in the downward direction.

In any of the above-mentioned examples, thecontrol circuit110 also can be programmed to control theelectric motor22 so as to move the plurality ofstairs20 along theinclined support14 at a predetermined speed, which can be saved in the memory.

In certain other examples, actuation of the secondoperator input device120 causes thecontrol circuit110 to control theelectric motor22 to move the plurality ofstairs20 in theupward direction26 along theinclined support14 until a predetermined time after actuation of the secondoperator input device120 ceases. In these examples, it can be beneficial to locate the secondoperator input device120 so that thesecond input device120 is accessible to the operator when the operator is standing on the ground next to the entryway of the plurality ofstairs20, but is not accessible to the operator once the operator has boarded the plurality ofstairs20 and is located on a position wherein it is possible to provide operator inputs to the operator input devices at theupper end portion18 of thestair climber apparatus10. For example, the operator can begin to actuate the secondoperator input device120 to initiate movement of the plurality ofstairs20. As the operator boards the plurality ofstairs20, the operator can release the secondoperator input device120 and the movingstairs20 can carry the operator up onto theinclined support14. After a predetermined time period, thecontrol circuit110 can be programmed to stop movement of the plurality ofstairs20, thereby positioning the operator in the center of the inclined support. One example of this type of configuration is shown in the figures, wherein the secondoperator input device120 is located on thehandles35 and faces away from the plurality ofstairs20.

Each of the above embodiments can be programmed into thecontrol circuit110 so as to automatically occur when the operator actuates the secondoperator input device120. The secondoperator input devices120 can include switches, control panels, and/or the like, wherein the operator can selectively control the direction, time, and speed of movement of the plurality ofstairs20 so as to facilitate easier mounting onto the plurality ofstairs20.

FIG. 8 depicts one example of a method of operating thestair climber apparatus10 according to the examples described herein above. Atstep200, thecontrol circuit110 receives a boarding command from the secondoperator input device120, as input by an operator standing on the ground adjacent thelower end portion16. Atstep202, thecontrol circuit110 is programmed to determine whether the plurality ofstairs20 is currently moving. If yes, atstep204, thecontrol circuit110 is programmed to ignore the boarding command. If no, atstep206, thecontrol circuit110 is programmed to causes themechanical brake48 to move from the noted locked position to the unlocked position. Thereafter, atstep208, thecontrol circuit110 is programmed to control theelectric motor22 to move the plurality ofstairs20 along theinclined support14 to bring a next stair in the plurality ofstairs20 into the noted lowermost position at thelower end portion16. Thecontrol circuit110 can be programmed to operate in a number of different ways, as described herein above. For example, atstep210, thecontrol circuit110 is programmed to determine whether the plurality ofstairs20 have been moved a predetermined distance. This can be determined based upon feedback from theencoder111. If no, atstep208, thecontrol circuit110 is programmed to continue to move the plurality ofstairs20. If yes, at step212, thecontrol circuit110 is programmed to control theelectric motor22 to slow the plurality ofstairs20 down to a zero speed. In another example, atstep214, thecontrol circuit110 is programmed to determine whether a predetermined time period has elapsed since the operator input the boarding command. If no, atstep208, thecontrol circuit110 can be programmed to continue to move the plurality ofstairs20. If yes, at step216, thecontrol circuit110 can be programmed to control theelectric motor22 to slow the plurality ofstairs20 down to a zero speed.

In yet another example, atstep218, thecontrol circuit110 is programmed to determine whether the secondoperator input device120 has been released. If no, atstep208, thecontrol circuit110 is programmed to continue to control theelectric motor22 to move the plurality ofstairs20. If yes, atstep220, thecontrol circuit110 can be programmed to determine whether a predetermined time period has elapsed. If no, thecontrol circuit110 can continue to control theelectric motor22 to move the plurality ofstairs20 atstep221. If yes, atstep222, thecontrol circuit110 can control theelectric motor22 to stop the plurality ofstairs20. This example applies where the operator first inputs the boarding command to the secondoperator input device120 and thereafter releases the secondoperator input device120 once the operator has boarded the plurality ofstairs20.

During further research and development, the present inventors have determined that it is desirable to provide a stair climber apparatus and method that better identifies a situation where an operator may have stepped off and/or fallen from the machine, and thereafter more quickly decrease the speed of the plurality of stairs down to a zero speed. This can avoid potential injury to the operator, which can occur if the operator falls and the plurality ofstairs20 continue to move.

As described herein above, in certain examples, thecontrol circuit110 is programmed to control the speed of theelectric motor22 and the output direction of theelectric motor22 between the noted forward and reverse directions. Thecontrol circuit110 also is programmed to control the speed of theelectric motor22 to maintain a constant speed of travel of the plurality ofstairs20 in thedownward direction24 along theinclined support14 as the operator is stepping on the plurality ofstairs20 in theupward direction26. To achieve this, thecontrol circuit110 normally controls theelectric motor22 to apply a braking force (i.e. to resist) movement of thestairs20 in the downward direction caused by the operator's stepping motion. In other words, thecontrol circuit110 typically will control the output of theelectric motor22 in the reverse torque direction to brake and maintain constant speed of travel of the plurality ofstairs20 along theinclined support14 as the operator is stepping in theupward direction26 on the plurality ofstairs20. Thecontrol circuit110 typically will control theelectric motor22 in the forward torque direction to drive the plurality ofstairs20 and thereby maintain the constant speed of travel of the plurality ofstairs20 along theinclined support14 when the operator stops stepping in theupward direction26 on the plurality ofstairs20, for example when a fall occurs. Advantageously, in this example, thecontrol circuit110 is further programmed such that when a change in output torque direction of theelectric motor22 is required to maintain the noted constant speed of travel of the plurality ofstairs20, thecontrol circuit110 automatically controls the speed of theelectric motor22 down to a zero speed. Thereafter, thecontrol circuit110 can optionally be programmed to actuate themechanical brake48 out of the unlocked position and into the locked position to secure the plurality ofstairs20 in position.

FIG. 9 depicts one example of a method according to the above described embodiment. Atstep300, thecontrol circuit110 is programmed to control the speed of theelectric motor22 to a constant speed, which optionally can be a speed that is input by the operator via the first input device19. Atstep302, thecontrol circuit110 is programmed to identify when a change in output torque direction of theelectric motor22 is required to maintain that constant speed. If no, thecontrol circuit110 continues operation atstep300. If yes, atstep304, thecontrol circuit110 is programmed to control speed of the electric motor down to zero speed. Atoptional step306, thecontrol circuit110 can be programmed to apply themechanical brake48 into the locked position.

In certain examples, thecontrol circuit110 can be programmed to instantaneously act to reduce the speed of theelectric motor22 to a zero speed when a change in output torque direction occurs; however in other examples, thecontrol circuit110 can be programmed to wait to act depending upon the current speed of movement of the plurality ofstairs20 and/or depending upon the amount of time that has elapsed since the change output direction occurred. For example, thecontrol circuit110 can be programmed to react slower to changes in output direction that occur at lower speeds than changes in output direction that occur at higher speeds. In some examples, thecontrol circuit110 can operate based upon input from a timer wherein thecontrol circuit110 only controls the speed of theelectric motor22 down to the noted zero speed after a predetermined time period has elapsed since the change in direction of the electric motor torque output has occurred. This accommodates situations where the operator might be stepping up more than one step at a time, for example. In other examples, thecontrol circuit110 can be programmed to control the speed of theelectric motor22 down to zero speed only when the speed of theelectric motor22 is above a speed threshold that is saved in the memory.

In certain other examples, thecontrol circuit110 can be programmed to control the speed of theelectric motor22 down to the noted zero speed only after (1) a first time period elapses (e.g. two seconds) or (2) a second, greater time period elapses and the speed of theelectric motor22 is above a threshold speed. This accommodates different exercise activities wherein the plurality ofstairs20 are moving various speeds and potentially more than one step are being taken by the operator at a time.

FIG. 10 depicts another example of a method according to the above described embodiments. Atstep400, thecontrol circuit110 is programmed to control the speed of theelectric motor22 to a constant speed. Atstep402, thecontrol circuit110 is configured to identify when a change in output torque direction of theelectric motor22 is required to maintain the noted constant speed of the plurality ofstairs20. If no, thecontrol circuit110 continues to operate atstep400. If yes, atstep404, thecontrol circuit110 identifies whether a first predetermined time period (e.g. two seconds) has elapsed. If yes, atstep406, thecontrol circuit110 controls the speed of theelectric motor22 down to a zero speed. If no, atstep408, thecontrol circuit110 identifies whether the speed of theelectric motor22 is above a threshold speed stored in the memory and a lesser, second threshold time period has elapsed. If yes, thecontrol circuit110 continues operation atstep400. If no, atstep410, thecontrol circuit110 controls the speed of theelectric motor22 down to a zero speed.

Claims (13)

What is claimed is:

1. A stair climber apparatus comprising:

a frame having an inclined support;

a plurality of stairs that are connected together in series and configured to travel around the inclined support;

an electric motor that is operably connected to the plurality of stairs and configured to start, maintain and stop travel of the plurality of stairs around the inclined support;

a controller that is configured to

(i) control a speed of the electric motor and an output torque direction of the electric motor so as to maintain a constant speed of travel of the plurality of stairs in a downward direction along the inclined support, and alternately to

(ii) control the speed of the electric motor down to a zero speed so as to stop travel of the plurality of stairs along the inclined support;

wherein as an operator steps on the plurality of stairs in an upward direction along the inclined support, the controller is configured to control the speed of the electric motor and the output torque direction of the electric motor to maintain the constant speed of travel of the plurality of stairs in the downward direction along the inclined support;

wherein thereafter when the operator steps off of the plurality of stairs, the controller is configured to control the speed of the electric motor and change the output torque direction of the electric motor to thereby maintain the constant speed of travel of the plurality of stairs in the downward direction along the inclined support; and

wherein thereafter, based directly upon the change in output torque direction of the electric motor, the controller is further configured to automatically control the speed of the electric motor down to the zero speed.

2. The stair climber apparatus according toclaim 1, further comprising an input device via which the operator can input the constant speed to the controller.

3. The stair climber apparatus according toclaim 2, wherein the input device is disposed on top of the inclined support.

4. The stair climber apparatus according toclaim 1, wherein the controller is configured to control the speed of the electric motor down to the zero speed only after a predetermined time period elapses after the change in output torque direction of the electric motor.

5. The stair climber apparatus according toclaim 1, wherein the controller is configured to control the speed of the electric motor down to the zero speed only when the speed of the electric motor is above a threshold speed after the change in output torque direction of the electric motor.

6. The stair climber apparatus according toclaim 1, further comprising a timer that is configured to count a time that elapses after the change in output torque direction of the electric motor,

wherein the controller is configured to control the speed of the electric motor down to the zero speed only after the timer counts a time that equals a predetermined time period from the change in output torque direction of the electric motor; and

wherein when, after the change in output torque direction of the electric motor, the controller causes a subsequent change in output torque direction of the electric motor in order to maintain the constant speed of travel of the plurality of stairs in the downward direction along the inclined support, the controller is configured to reset the timer to zero.

7. The stair climber apparatus according toclaim 1, further comprising a mechanical brake that is movable between a locked position wherein movement of the plurality of stairs by the electric motor is prevented and an unlocked position wherein movement of the plurality of stairs by the electric motor is permitted.

8. The stair climber apparatus according toclaim 1, further comprising an encoder that is configured to detect the speed of the electric motor and the output torque direction of the electric motor.

9. The stair climber apparatus according toclaim 1, wherein the electric motor is an asynchronous electric motor.

10. A method of operating a stair climber apparatus having an inclined support and a plurality of stairs that are connected together in series and configured to travel around the inclined support, the method comprising:

controlling a speed of an electric motor and an output torque direction of the electric motor that is operably connected to the plurality of stairs and configured to start, maintain and stop travel of the plurality of stairs along the inclined support;

controlling, as an operator steps on the plurality of stairs in an upward direction along the inclined support, the speed of the electric motor and the output torque direction of the electric motor to maintain the constant speed of travel of the plurality of stairs in the downward direction along the inclined support;

controlling thereafter, when an operator steps off of the plurality of stairs, the speed of the electric motor and changing the output torque direction of the electric motor to thereby maintain the constant speed of travel of the plurality of stairs in the downward direction along the inclined support; and automatically controlling, based directly upon the change in output torque direction of the electric motor, the speed of the electric motor down to a zero speed.

11. The method according toclaim 10, further comprising controlling the speed of the electric motor down to the zero speed only after a predetermined time period elapses.

12. The method according toclaim 11, further comprising controlling the speed of the electric motor down to the zero speed only if the speed of the electric motor is above a threshold speed.

13. The method according toclaim 11, further comprising subsequently moving a mechanical brake into a locked position wherein movement of the plurality of stairs by the electric motor is prevented.

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